TriangleTube PTRKIT111 Manuale utente

Gas Valve Replacement Kit

Kit Part Number: PTRKIT111

Parts List

1. Honeywell Gas Valve VK4115V (120V)

2. Gas Valve/Orifice Gasket

3. Torex Screws (3 pcs)

4. Venturi/Blower Housing Gasket

5. # 25 Torex Wrench.

Recommended tools:

A. Pipe Wrench.

B. Phillips Screw Driver.

C. Flat Blade Putty Knife.

D. # 25 Torex Wrench. (Furnished in Kit.)

Failure to follow instructions below can result

in severe personal injury or damage if ignored.

• Instructions are for a qualified installer/ser-

vice technician.

• Read all instructions before proceeding.

• Follow instructions in proper order.

For your safety, turn off electrical power

supply at service panel before proceeding to

avoid possible electrical shock hazard.

Failure to do so can cause severe personal

injury or death.

This kit is designed for gas valve replace-

ment on the Prestige TriMax 60, 110, 175,

250 and Prestige TriMax Excellence prod-

ucts. Boiler serial number must start with

PT.

This kit M ST NOT be used on Prestige

Boilers equipped with MCBA Controls.

These boilers have a serial number starting

with PS.

NOTICE

WARNING

NOTICE

Indicates a potentially hazardous situation

which, if ignored, can result in serious

injury or substantial property damage.

Indicates special instructions on installa-

tion, operation or maintenance, which are

important to equipment but not related to

personal injury hazards.

NOTICE

WARNING

Gas Valve Replacement Kit

PRESTIGE BOILER INSTR CTIONS:

1. Turn power to the unit “OFF”.

2. Shut off the gas supply to the boiler at the main

manual shutoff valve.

3. Remove the front jacket panel.

4. Remove the air inlet elbow from the venturi.

5. Remove the olex plug from the gas valve.

6. Disconnect the gas supply piping inside the

PRESTIGE at the brass union located just

before the gas valve.

7. Remove and save the two Torex screws attach-

ing the venturi / gas valve assembly from the

blower housing. See Fig.1. Remove the venturi

/ gas valve assembly from the blower housing.

Use the Torex wrench supplied in the kit to

remove screws.

There is a gasket between the venturi and blow-

er housing. If gasket “sticks” to the blower

housing use a flat blade putty knife to remove

any gasket material. Make sure not to scratch or

score the mating surface on the blower housing.

8. Remove the three screws attaching the gas

valve to the venturi. Use Torex wrench sup-

plied in kit to remove screws. Note orientation

of the venturi to the old gas valve for reassem-

bly of the venturi on the new gas valve.

9. Reassemble the new gas valve, gas valve/orifice

gasket and the three Torex screws from the kit

and reassemble the gas valve to the venturi. See

Fig. 2.

Ensure the gas valve/orifice gasket is in place

before reassembling the gas valve and venturi.

Failure to do so can result in death, serious

injury or substantial property damage.

NOTICE

WARNING

1. Gas Valve

2. Venturi

3. Gas Valve Fitting

4. Venturi ounting screws.

Attaching Gas Valve/Venturi to Blower

Housing

Fig. 1: Prestige Burner Assembly

Gas Valve Replacement Kit

For propane installations a brass orifice is locat-

ed inside the gas valve/orifice gasket. This ori-

fice must be placed inside of the new gas

valve/orifice gasket before reassembly.

Failure to insert the propane brass orifice, on

propane installations, before reassembling the

gas valve and venturi can result in the produc-

tion of carbon monoxide due to incomplete com-

bustion and may result in death, serious injury

or substantial property damage.

10. With the venturi to blower gasket in place,

reassemble the venturi / gas valve to the blower

housing using the two mounting screws from

step 7.

For the reassembly process do not use adhesive

on any gasket surface.

11. Reconnect the olex plug to the gas valve elec-

trical connection.

12. Reconnect the brass gas piping union connec-

tion. Open the main manual gas shutoff valve

before placing the PRESTIGE unit back into

operation check and test all gas connections for

leaks. Repair leaks if found.

Do not check for gas leaks with an open flame.

se a bubble test. Failure to check for gas leaks

can cause severe personal injury, death or sub-

stantial property damage.

13. Reattach the air inlet elbow to the venturi.

14. Reattach the front jacket panel.

15. Turn the electrical power “ON” to the PRES-

TIGE to return the unit back into service.

NOTICE

WARNING

NOTICE

Venturi

Orifice

Gas Valve

Gasket

Gas Valve

Fig. 2: Gas Valve / Venturi Assembly - PRESTIGE Solo 60/110/175/250

Gas Valve Replacement Kit

COMB STION TEST

1. The installer UST perform a complete com-

bustion check to ensure the following combus-

tion levels are met at high and low input firing

rates and the burner is operating at optimum

conditions.

Table 1: Combustion Settings

The combustion testing and adjustments

must be performed by a qualified installer,

service agency or the gas supplier. All com-

bustion measurements must be perform with

calibrated equipment to ensure proper read-

ings and accuracy.

Failure to perform a complete combustion

test at both high and low input rates may

result in incomplete combustion and the pro-

duction of carbon monoxide, which can

cause severe personal injury, death or sub-

stantial property damage.

2. Test for CO2 or O2 and for CO during high fir-

ing rate. The combustion readings should be

within the range listed in Table 1. The CO level

should not exceed 100 ppm when combustion

is correct. Perform the following procedure to

manually place the burner into high fire.

a. Press the round INSTALLER button. See

Fig. 3.

b. Enter the installer access code “054” by

using the LEFT and RIGHT buttons to

select a digit and the P and DOWN but-

tons to change the digit. Press the OK but-

ton to enter the access code.

c. Press the RIGHT button to highlight the

anual Operation icon then press the

OK button.

d. Press the OK button while the FAN icon is

highlighted to manually fire the burner and

power the CH circulator.

An adequate CH load must be present to dis-

sipate the heat generated during the combus-

tion test. If an adequate CH load is not avail-

able, an indirect water heater can be used to

dissipate the heat by creating a DHW call

which will enable the DHW circulator.

e. Press the LEFT and RIGHT buttons to

adjust the firing rate from 0% to 100%.

Hold down the LEFT or RIGHT button to

rapidly increase or decrease the firing rate.

WARNING

NOTICE

Natural Gas Propane

O2 Min. 2.30% 2.70%

O2 Max. 5.30% 4.70%

CO2 Min. 8.80% 10.70%

CO2 Max. 10.50% 12.00%

CO Max. 100 ppm 100 ppm

Manual Operation

Released

O

CH1

FAN

DHW

SYS

CH2

Installer

Button

Fig. 3: Trimax Navigation Buttons

Gas Valve Replacement Kit

f. Press the OK button while the FAN icon is

highlighted to shutdown the burner.

g. Cycle power to the Prestige once combus-

tion testing is complete to return to normal

operation.

The combustion levels should be measured at

high firing rate. If the combustion levels are

not within the range given in Table 1 for the

firing rate, shut the boiler down and contact

Triangle Tube Engineering Department.

Failure to comply with this requirement

could result in severe personal injury, death

or substantial property damage.

If the combustion levels during high fire is outside

the recommended combustion settings adjust the

THROTTLE SCREW (see Fig. 4) as follows:

Counter-clockwise adjustment of the throttle

screw at high fire:

O2decreases and C02increases

Clockwise adjustment of the throttle screw at

high fire:

O2increases and CO2decreases

4. Once the combustion level is set at high fire,

manually place the boiler into low fire mode by

pressing the LEFT button to adjust firing rate

down.

5. If the combustion level during low fire is not

within +/-0.2% of the combustion level mea-

sured at high fire, adjust the metal offset screw

inside the brass fitting on the top right of the gas

valve (see Fig. 4) as follows.

Counter-clockwise adjustment of offset screw at

low fire:

O2increases and O2decreases

Clockwise adjustment of offset screw at low fire:

O2decreases and CO2increases

WARNING

Offset Pressure

Cover Screw

Throttle

Screw

Fig. 4: Combustion Adjustment - Prestige Burner

2011-53 PrestigeGas Valve Repl. Kit_Tri ax

Date: 12/8/11

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